PROCESS 



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DXYAGETY1ENE WELDIN 



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Class 
Book. 



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COPYRIGHT DEPOSIT; 



INSTRUCTIONS 

ON 

WELDING and CUTTING of METALS 



QC ^DO 



Oxy acetylene Process 



VULCAN PROCESS CO. 

Minneapolis, Minn. Cincinatti, Ohio 



(Copyrighted 1914) 






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MAY 25 1914 

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CONTENTS 

Chapter I — History. 

Chapter II — Calcium Carbide. 

Chapter III — Acetylene Gas. 

Chapter IV — Oxygen Gas. 

Chapter V — Hydrogen Gas. 

Chapter VI — Use of the Oxyacetylene Flame. 

Chapter VII — Vulcan Automatic Acetylene Gen- 
erator. 

Chapter VIII — -Welding and Cutting Torches and 
their Regulation. 

Chapter IX — Regulators and Indicators. 
Chapter X — Operation of Plants of Compressed 
Gases, also Generator Plant. 

Chapter XI — Preheating. 

Chapter XII — General Welding Instructions. 

Chapter XIII — Welding Rods and Fluxes. 

Chapter XIV — Metals and their Properties. 

Chapter XV— Boiler Work. 

Chapter XVI — Carbon Destroyed in Cylinders. 




Broken and Useless. 




Welded and Good as New. 




View of a corner of 
one of our 100 cell ox- 
ygen and hydrogen 
generating plants, 
making 7500 to 10,- 
000 feet of oxygen 
gas and 15,000 to 
20,000 feet of hydro- 
gen gas, of over 99 
per cent purity per 
day, also showing 150 
h. p. motor generatingj 
plant. 



Greatest success in 
welding is attained 
by using absolutely 
pure oxygen in 
blow torch. Guts il- 
lustrate plants mak- 
ing these gases. 

Cut of our approv- 
ed automatic acety- 
lene generator which 
makes gas from car- 
bide at about %c 
per ft. when carbide 
is $3.75 per 100 lbs. 





Showing Interior 
View of Acetylene 
Generator. 




CHAPTER I. 
HISTORY. 

The powers used in welding- are not by any 
means new, but the application of these forces in 
new and unusual ways, particularly in Autogenous 



A Corner in our Laboratory. 

Welding, is comparatively new to the commercial 
world and a brief outline of development is profit- 
able reading. 

It is said that old Ninevah was illuminated with 



-S— 



artificial lights so brilliant that at times it was diffi- 
cult to distinguish night from day. This announce- 
ment may be somewhat exaggerated but only il- 
lustrates that the ancients had many secrets in the 
arts of various kinds, and particularly in the metal 




4>'^ 



Welding in Gear Teeth in Gas Tractor W T heel. 



world, that the moderns have as yet not achieved. 
The Damascus sword and special treatment of cop- 
per are illustrations of this kind ; and yet so 
extensive is the scientific knowledge in the labora- 
tory today that it would seem as if there are no 



secrets which are beyond the ken of the skilled 
chemist and his co-laborers who place before the 
commercial world the knowledge and skill of the 
field of research in this vast domain. Among the 
various scientific lines of work one of the interest- 
ing groups to see considerable change and develop- 
ment is the gas realm. In 1792 William Murdock, 
afi Englishman, lighted his workshop with gas ob- 
tained from soft coal ; ten years later extensive gas 
works were established at Birmingham, England. 
1803 saw the Lyceum Theatre, London, lighted 
with gas and in 1810 a powerful Company was 
formed to overcome the prejudice of the people of 
London. 




Showing Centrifugal Pump with IY2 ft. crack and patch 
6x9 in. successfully welded. 



-10- 



Oil gas and water gases have had to force their 
way into popular approval ; while last but by no 
means least, acetylene gas as recent as 1892 was 
discovered by accident by Thomas L. Wilson at 
Spray, North Carolina and was found devel- 
oped in a semi-calcium carbide formation in quan- 
tity large enough for commercial purposes, and 
Lord Kelvin this same year gives Mr. Wilson credit 
for this advance to science and commerce. 





Bosh Jacket Welded in Boiler Shop at Duluth, Minn. 



Extract of J. E. Johnson's letter of Feb. 11, 1913, 
relative to this work. 

"Roughly, the jacket is a truncated cone, eleven 
feet in diameter at the bottom and about sixteen 
feet in diameter at the top, by about nine feet high. 
Both top and bottom were flanged out horizontally 
to a distance of about three inches. The thickness 
of the metal is T /i inch throughout. 

The jacket was made up in four sections, which 
were welded together along the vertical joint. What 
we particularly desired was to get, first a smooth 



job, and second, only one thickness of metal. The 
first so that the cooling water would stay on the 
jacket better than it is possible for a film of water 
to do on such a surface when broken by seams and 
rivets, even though the latter be countersunk. The 
second latter to eliminate the greater liability to 
burning, due to double thickness of metal. 

We regard the construction as an eminently 
satisfactory one in both particulars. By chippings 
the exterior of the seam with a broad chisel and 
then grinding it we get a job as smooth as the rest 
of the sheet, and it is impossible to see without 
great difficulty where the joints are. 

The jacket has given us a minimum of trouble 
and if we are going to install another one, I should 
not hesitate to have it welded in the same way." 
Yours truly, 
J. E. Johnson, Jr., Manager. 

Mr. Johnson is well known on iron ranges and in 
the metal world. 



-13— 



CHAPTER II. 
CALCIUM CARBIDE 

from which is produced acetylene gas is a hard 
opaque, crystalline substance, known to the chem- 
ist as CaC 2 , merely an expression for one unit of 
mass of calcium, the metal which exists in lime, 
combined with two mass units of carbon. Calcium 
carbide is a compound which contains calcium and 
carbon only. The calcium in it is about 62^2 per 
cent and the carbon is 37^ per cent of the weight 




CBANK SHAFT BROKEN. 

6 in. crank shaft 11 feet in length, used in producer gas 

engine; successfully welded in our repair department. 

of the carbide. Calcium, a metal, and carbon, a 
substance like coal, are both contained in this ma- 
terial, calcium carbide, though the compound is so 
different from either constituent. 

Calcium carbide is generally of a dark brown 
or black color, sometimes described as dark gray, 
and sometimes as a bluish black, and often pos- 
sessing a reddish tinge. If broken while hot, the 
fracture exhibits considerable iridescence. It is 



-14- 




SAME CEAXK SHAFT WELDED. 
Good as new and working every day. 

brittle, and is more or less crystalline in structure. 
Its specific gravity is 2.22 to 2.26 ; it endures heating 
to redness without melting or suffering other 
change, though it softens and fuses under electric 



-15- 




Cylinder Broken and Useless. 




Welded and Good as New. 



-16- 



heat; it will not burn, except when highly heated in 
oxygen ; it looks like a mass of stone. A cubic 
foot of the crushed material weighs one hundred 
and thirty-six pounds and in weight, color and 
many physical characteristics it is frequently com- 
pared with granite. 

Calcium carbide may be preserved any length of 
time if kept sealed from air, but the ordinary mois- 
ture of the atmosphere gradually slakes it and it 
becomes changed on long standing, into slaked 
lime. This slaking power gives it a name, which 
is sometimes heard : Acetylene Lime. It always 
possesses a penetrating odor, which, however, is 
not due to the carbide itself, but to the fact that it 
is constantly affected by moisture, yielding minute 
quantities of acetylene, which accounts for the odor 
rather than the carbide itself. It is not affected by 
solvents, such as carbon bi-sulphide, petroleum, 
chloroform, ether or benzol, but if allowed to come 
into contact with water, or any mixture containing 
water, an immediate and vigorous decomposition 
takes place, evolving liberal quantities of gas ; it is 
unaffected by shock, concussion or age. 

Carbide is a safe substance to store or transport 
under proper conditions. Transportation lines ac- 
cord it the same classification rates as various other 
forms of hardware. It cannot explode, take fire, or 
otherwise do harm, being similar to lime in this 
respect also. Since even the slow action of moisture 
ordinarily present in the air will in time render 
carbide entirely useless, it becomes absolutely nec- 
essary, in order to securely preserve it, to pack it 
in perfectly tight, closely sealed containers, gener- 
ally drums or cans. Granted protection from water, 
no substance can be safer or less likely to cause 



trouble when stored or conveyed from place to 
place. Lime becomes very hot when acted upon by 
water; also so does carbide, and the only essential 
difference is that carbide, when it slakes with water, 
yields a combustible gas. Carbide decomposes with 
water in accordance with the following chemical 
equation. 

CaC 2 +2H 2 0=Ca (OH) 2+C2H2 
Carbide and water yield slake lime and acetylene. 

An easy calculation shows that sixty-four unit- 
weights of carbide require thirty-six of water, pro- 
ducing also seventy-four unit weights of slaked lime 
and twenty-six of gas. A pound of absolutely pure 
carbide yields five and one-half cubic feet of acety- 
lene. Yet, absolute chemical purity is not a prac- 
tical commercial possibility, and it is natural to sup- 
pose that commercial products of different manu- 
facturers will vary in purity. Calcium carbide is 
no exception. In practice, good carbide may gen- 
erally be expected to produce never less than four 
and a half cubic feet, measured at ordinary tempera- 
ture, and rarely more than five and one-fourth cubic 
feet per pound of carbide. It may be ordinarily 
calculated at five. It is important to remember 
that the exact proportional weights of water and 
carbide must always enter into combination, i. e., 
sixty-four of actual carbide to thirty-four of water, 
be it in ounces, pounds or tons; also that the same 
proportional weight of acetylene must always re- 
sult. Any apparent exception can only be due to 
impure carbide, loss of gas, or failure to secure 
complete consumption of material. 

The evolved gas does not take fire of itself but is 
easily lighted. The gas burns with a bright light, 
not brilliant, for it needs control to bring out this 



-18- 



property, and much smoke. In fact, soot in solid 
flakes may be seen floating through the air when 
the experiment is performed in this rough way. Car- 
bide is not inflammable, nor possessed of any explo- 
sive property such as is sometimes erroneously at- 
tributed to it. 

When water is sprinkled or sprayed upon car- 
bide, in not excessive quantities, the resultant slaked 
lime is left in a perfectly dry and dusty condition, 
occupying considerable more space than the original 
carbide. When more than enough water is em- 
ployed, the residuum will, of course, be wet, either 
pasty, or thinner if a large excess of water is em- 
ployed. 



—19- 



CHAPTER III. 

ACETYLENE GAS. 

Acetylene gas is commonly made by bringing to- 
gether calcium carbide and water. The chemical 
reaction is CaC 2 +H 2 0=C 2 0+CaO. When acety- 
lene is generated by this method a considerable 
amount of heat is liberated. To overcome this a 
large excess of water should be employed, and the 
carbide should be dropped into the water. The car- 




Illustrating portable plants with Vulcan Acetylene Gener- 
ator, also plant Nos. 3 or 4 when mounted on truck. 



-20- 



bide sinks to the bottom of the generator and the 
gas, upon being generated, rises to the top of the 
generator. As it passes upward through the water 
it is washed free from dust particles, and at the 
same time is cooled. Acetylene can also be pre- 
pared by dropping water upon the carbide. When 
this is done there is no provision for the absorption 
of the heat of chemical action. The gas, when thus 
rapidly generated, becomes hot and full of fine dust, 
making it objectionable for welding purposes. The 
way to avoid this is to generate the gas by what 
is termed a "carbide feed" generator; that is, by 
dropping the lumps of carbide into the water. At 
least one gallon of water to every pound of car- 
bide should be provided. A cut of one of the sim- 
plest generators is shown in Figure 1. This gen- 
erator is manufactured by the Northern Welding 
Company for the Vulcan Process Co. of Minne- 
apolis and Cincinnati, and not operated by the 
usual clockworks, regulating diaphragms, weights, 
etc. The pressure is regulated by means of a pat- 
ented by-pass arrangement, and the pressure does 
not vary perceptibly. By means of a simple de- 
vice the pressure can be set at any desired pressure, 
and this pressure will then be maintained until all 
of the carbide has been used up. 

The different manufacturers usually furnish com- 
plete instructions for operating their own makes of 
acetylene generators, and these instructions should 
be followed as closely as conditions will permit. 
Compressed dissolved acetylene can be obtained 
from one of the companies engaged in this busi- 
ness. Cylinders containing from 40 to 500 cubic 
feet of dissolved acetylene can be purchased. The 



-21— 



large cylinders, however, are quite heavy, weigh- 
ing as much as 435 pounds. 

The following is a summary of the different 
types of acetylene generators, and their advantages 
and disadvantages : 

Drip Type Generators. 

1. Over-heating. 

2. After-generation. 

3. Incomplete decomposition of carbide. 

Flooding Type Generator. 

1. Over-heating. 

2. After-generation. 

3. Extra gasometer necessary to avoid undue 
pressure in generator. 

Dipping Type Generator. 

1. Excessive over-heating, hence dangerous. 

2. After-generation present.. 

Carbide-to-Water Type Generator. 

1. Over-heating impossible if water is in excess. 

2. After-generation impossible. 

3. Lack of over-heating causes pure gas to be 
evolved. 

4. Dust is washed out of gas, as gas bubbles 
up through water. 



-22— 




Showing oxygen cell plant making 997c purity oxygen from 
water by electrolysis. 



CHAPTER IV. 



OXYGEN GAS 

is the most widely distributed of all the elements, 
and was isolated first by Joseph Priestly in 1774, 
the following year Lavoisier gave the opinion that 
this substance was same as in air and gave it the 
name of oxygen. It is heavier than air in the pro- 
portion of 1 to 1.056. It was liquified for the first 
time in 1877. For general commercial purposes it 
can be made from chlorate of potash (crystals) with 
best quality manganese dioxide in the proportions 
of 100 pounds of the chlorate of crystal potash to 



13 pounds of the manganese dioxide. (Note 
weight, not volume.) These two chemicals are first 
thoroughly mixed and then placed in a retort made 
for that purpose, and external heat applied. This 
liberates the oxygen, which passes off through 
washers and into the pressure tanks direct or into a 
gasometer. If first run into a gasometer it is piped 
from there, and by means of a specially constructed 
oxygen compressor is compressed into pressure 
tanks. The cost of producing chemical oxygen, of 
course, depends largely upon the price of the chem- 
icals. The usual market price, in quantity, of chlo- 
rate of potash crystals, is 9y 2 c per pound. The best 




Cut showing chemical oxygen plant, which we do not 
recommend only in emergency cases as the gas is not as 
pure. 1 foot of Electrolytic oxygen gas goes as far as 2 
feet of Chemical gas in cutting and same pro rata in 
welding. 




Showing Hydraulic 3 cylinder pump, capacity 12 cub. ft. 
per minute, compressing oxygen gas from 1500 to 2200 lbs. 
pressure. 

The most simple and satisfactory pump for plants up to 
10,000 ft. of gas per day. 



25- 



grade of manganese dioxide, 2%c. To this should be 
added freight and cartage. Including the cost of 
manufacture, and figuring the cost of chemicals, as 
above stated, the oxygen would cost approximately 
3c per cubic foot. 

The greatest precaution must be used in prevent- 
ing the smallest portion of carbon, such as in paper, 
small pieces of wood, grease, or any other inflam- 
mable material, becoming mixed with the com- 
pound, as if such should be accidentally placed in 
the retorts with the chlorate of potash, an inflam- 
mable gas would be created when the retort is heat- 
ed, and this might cause an explosion. For this 
reason the manganese dioxide should be of the best 
quality, and it should be screened through a fine 
sieve before mixing with the potash, and no oppor- 
tunity should be permitted for the admission of 
any such inflammable materials after it has been 
screened. 




Aluminum Frame Broken. 
—26— 



In the manufacture of chemical oxygen it should 
be passed through a chemical solution to purify it 
of the chlorine gas. The formula for this solu- 
tion is furnished by the manufacturers of chemical 
oxygen plants. 

Some companies manufacture oxygen for com- 
mercial purposes from the air. This entails a large 
investment, and such an equipment cannot be in- 
stalled by the ordinary user of oxygen. The oxy- 
gen made from the air can be used for welding, 
although, on account of the nitrogen it contains, it 
is not nearly as satisfactory as the pure oxygen 
made by the electrolysis of water. The latter meth- 
od produces the purest oxygen, which is far super- 
ior for both welding and cutting. It is practically 
100% pure, and is used for medicinal purposes, as 
well as for welding. The writer strongly recom- 
mends the electrolytic oxygen where it can be pro- 
cured in pressure cylinders at a cost of 3>4c per 
cubic foot or less. 




Same frame welded good as new. 
—27— 



CHAPTER V. 

HYDROGEN GAS. 

Water when decomposed by process of elec- 
trolysis produces two gases, the volumetric propor- 
tion being Hydrogen in two parts and Oxygen one 
part. Hydrogen is also found in considerable quan- 
tity in animal and vegetable matter, is the light- 
est of all gases, air weighing 14y 2 times this gas. 
This gas is highly inflammable and is of consider- 
able use when united with oxygen in metal cutting. 
Its heat however is about 4100° Fhr., while that 
of oxy-acetylene is approximately 6300° Fhr. In 
cutting steel it leaves a comparatively smooth wall 
with the metal but little effected by oxidation on 
either side of the cut. Steel up to 16" thickness 
has been successfully cut by these two gases. Thin 
metals up to 3/16" thick can also be successfully 
welded by these two gases, but for rapid and eco- 
nomical welding the oxy-acetylene flame is decid- 
edly its superior. 

This gas, while a by-product of oxygen from 
water, is daily increasing in its usefulness. Lead 
burning, various uses in electric work, heating, 
laboratory, soap making, vacuum work, balloon fill- 
ing, gem production, etc., etc., are some of its prin- 
ciple uses. 



-28— 




Illustrating regulation of the flame. Top figure showing 
excess of oxygen; middle figure showing neutral flame; 
lower figure showing excess of acetylene. 



CHAPTER VI. 

USE OF THE OXY-ACETYLENE FLAME. 

Almost all metals can be united by autogenous 
welding which is simply uniting these metals with- 
out compression or hammer blows, but by heat 



C0+OC0 2 
H 2 + OH 2 




Phases of the combustion in the oxy-acetylene flame. 



alone, the metal at point of fusion flowing together 
and in majority of cases being recast locally with 
extra metal of same kind being used when neces- 
sary. 

The manufacturer in almost all lines of metal 
work is daily finding new adaptations for this great 
power, while those who repair all kinds of broken 
metal are daily adding to their knowledge of this 
art which soon makes them skilled in this profitable 




Showing a complete oxy-acetylene plant made in various sizes, 
all ready for work. 



business. It is of considerable value for cutting 
steel and iron in wrecking buildings, bridges, etc. 
Every week sees new uses for this great force from 
nature's laboratory. Chief among ways that appar- 
atus, noted in this book, will be called on for work, 
will be making good as new, broken parts of autos, 
traction engines, general machinery (of any size), 
navy yard and railroad shop work and all kinds of 
farm implement work. 



CHAPTER VII. 



VULCAN AUTOMATIC ACETYLENE 
GENERATOR. 

Chapter three outlines the various types of gen- 
erators that can be used to produce acetylene gas. 
In reading over the advantages and disadvantages 
of the different methods of the generation of acet- 
ylene it will be noted that the "carbide to water 
feed" generator has none of the disadvantages of 
the other types, but does have a great many ad- 
vantages that are not possessed by the other gen- 
erators. 

Of the two styles of generators, low and me- 
dium pressure, the latter is the better for welding as 
the acetylene, as well as the ovygen, should be de- 
livered to the gas mixing chamber of the welding 
torch under pressure. Where both gases are thus 



—31- 



combined under a positive, even pressure, their mix- 
ture is more complete — assuming that the mixing 
chamber of the torch is properly constructed. Un- 
less this thorough mixing of the two gases takes 
place, the result will be incomplete combustion, 
hence waste of gas and loss in efficiency. 

With the low pressure or gasometer type of 
generator, the injector type of torch is principally 
used. By this is meant that the oxygen under high 
pressure, in passing through the mixing chamber 
of the torch, sucks the acetylene through with it. 
In this way the two gases are not thoroughly 
mixed, resulting in waste of gas as well as poor 
welding. The feeding mechanism of most pressure 
generators now on the market are operated by 
means of a complicated clock-work with pulleys 
and weights, leather diaphragms, etc. These fre- 
quently get out of order at just the time when the 
operator needs the gas the most and the resulting 
delays are expensive as well as annoying. 

The Vulcan automatic pressure generator oper- 
ates on an entirely new principle. It is the only ap- 
proved pressure generator manufactured that oper- 
ates the feeding mechanism by means of the pres- 
sure of the gas. This ingenious device is, of course, 
fully protected by patents and several leading acet- 
ylene generator dealers have adopted the Vulcan 
generator to the exclusion of the old type. 

The plan of this generator is such that the torch 
demand automatically regulates the making of the 
gas ; that is, as gas is consumed in the torch or 
torches, as the case may be, gas is made in same 
proportion in the generator to supply that gas con- 
sumption in the torch, the work is simple, positive 
and accurate, does not vary as in other types of 



pressure generators and in a word places this gen- 
erator in a class by itself. Remember this gen- 
erator has a constant feed at a variable speed as 
contrasted with the ordinary type, constant speed 
starting and stopping between given limits. The 
rate at which the carbide is fed in our generator 
varies directly with the rate at which the gas is used, 
in other words no more carbide is ever fed to the 
generator than is absolutely necessary at that per- 
ticular moment. This means that the heat gener- 
ated is always and positively at a minimum, be- 
cause only the minimum amount of carbide needed 
is fed at any one time. For the same reason, it 
means that after generation is eliminated to the 
greatest possible degree. Due to the unique feed, 
no carbide can be fed unless the gas is being used 
through the service pipe. Finally, any accident 
any leaky valve, a leaky gasket, leaky joint or a 
leaking blow off makes the generator in-operative. 
These are some of the reasons why we know 
that our generator is not only the safest but also 
the most economical that has been built, to our 
knowledge. To make these facts still more clear, 
we add a description of the generator and its oper- 
ation. 

Acetylene Generator at top of next page when 
filled with water up to No. 7 and carbide in No. 4 
is ready to make gas automatically as demand of 
welding torch requires gas. 




Acetylene Generator And Directions How To 
Operate. 

To fill generator, open vent valve by turning 
lever No. 1 one-quarter turn. This releases all 
pressure in generator. Next revolve agitator han- 
dle No. 10 and open sludge cock by turning lever 2 
one-quarter turn. This also removes the guard 
over filling cap 4. After the sludge has drained off 
release latch 5, which permits closing sludge cock 
without replacing filling cap guard. Now bring 



—34- 



lever 3 to a horizontal position and rill generator 
with water through funnel 6 until water flows out 
of pipe 7 of the overflow chamber. Fill carbide 
hopper with l^x^-inch carbide through opening 
at 4. • 

Replace in following order : First filling-hole- 
cap No. 4; lever No. 3; and last, lever No. 1 which 
locks all parts. 

Fill motor case No. 1 and regulator chamber No. 
11 with water through filling plug 8. Pipe No. 13 
is the blow off, and should be piped without traps 
to the outside of the building, and with as few 
elbows as possible, the pipe line terminating in an 
elbow looking down to prevent the clogging by 
snow, ice, etc. The pipe 14 is connected to the 
supply line. 

Revolve feed screw sprocket No. 9 until several 
pounds pressure is shown on indicator. Replace 
drive chain and the generator is ready for opera- 
tion. The gas will automatically rise to the proper 
pressure, the carbide being fed by the power of the 
gas operating the motor. The regulating device 
in chamber No. 11 starts and stops the feeding 
means automatically. Carbide will positively not 
be fed into the water unless gas is being used from 
the supply line. If the motor continues to revolve 
after all burners are shut, look for a leak in supply 
line. Carbide is fed at a rate proportionate to the 
rate of flow of gas through motor, up to a pre- 
determined volume, which is regulated at the fac- 
tory to prevent too rapid generation which might 
be brought about either through ignorance or ac- 
cident. 

Always keep the motor case filled with water, 

—35— 



for without it the generator will become inoper- 
ative. 

If the pressure in the generator gradually drops, 
look for a serious leak in the generating chamber 
in such places as the filling hole cap, etc., since the 
ratio between the motor and the feed screw is such 
that when all the gas passes through the motor 
just enough carbide is fed to keep up the proper 
pressure, and if part of the gas generated escapes 
before entering the motor case it does not furnish 
power to feed carbide, which is necessary to gen- 
erate gas to take its place. To make this more 
clear, four cubic feet of gas must pass through the 
motor to feed one pound of carbide, and if two 
cubic feet escape before passing through the 
motor only one-half a pound of carbide will be fed, 
hence the gradual drop in pressure. 




The proper position of welding torch for filling in of 
holes. 



-;;<;- 




Proper method of holding welding roc 




Circular movement of the welding torch during the exe- 
cution of the weld. 




The metal added must not fall, drop by drop, into the 
weld. 




Side to side movement for the execution of welds of 
greater thickness. 



—38— 



CHAPTER VIII. 

WELDING AND CUTTING TORCHES AND 
THEIR REGULATIONS. 

Generally speaking, there are two types of weld- 
ing torches, the one being known as the low pres- 
sure type, and the other as the high pressure torch. 
The principle of the low pressure torch is based on 
that of the injector, the acetylene, which is under 
pressure of only a few ounces per square inch, be- 
ing drawn by suction produced by the flow of ox- 
ygen. The mixture then passes out of the tip. If 
the flow of the oxygen should vary, the proportion 
of the acetylene would not be constant, and any 
variation in either direction will produce either an 
oxidizing or carbonizing flame. The low pressure 
torch has now been largely superseded by the high 
pressure torch, both in Europe and in this country. 
In the high pressure torch both the acetylene and 
oxygen are under an appreciable pressure, which 
results in a positive mixture under all conditions. 
The pressure of each gas is kept constant, as re- 
quired by adjustable reducing valves. The tips can 




-:'!9- 



be detached, and several of different capacity are 
supplied with each torch, which allows a consider- 
able range of work to be carried on without chang- 
ing torches. 

The writer can highly recommend the "Vulcan" 
torch or blowpipe. It is much more economical in 
the consumption of oxygen and acetylene than any 
other torch now offered to the trade, and is so 
easily adjusted that there is little or no danger of 
burning- or carbonizing the metal, as is the case 
with most of the other makes of torches. The 
reason for this, is the ingenious arrangement for 
the perfect mixture of the two gases before enter- 
ing the welding tip. This is of the utmost im- 
portance, as when there is an excess of oxygen 




To wold interior surface of a motor cylinder cut out 
latch "A" weld crack "C" then weld patch "A" in 
space "B." 



—40— 



the flame will oxidize or "burn" the metal, and 
when there is an excess of acetylene the flame car- 
bonizes the metal. 

A great many torches "flash back," or burn in 
the torch tip or head whenever the tip comes in con- 
tact with the metal. This defect, as every welder 
knows, is common in practically every type of 




Cutting torch which cuts steel 2" thick x 1 ft. wide in 
1 minute; or cuts a battleship slab of steel 4 ft. x 4" in 7 
minutes. 



torch, except the "Vulcan" type above referred to. 
Dissolved acetylene can also be used with this 
torch. 

We submit our outline of operation for our cut- 
ting - torch ; the acetylene hose is connected on in 
the same way as when getting it ready for welding. 
The oxygen hose is put on the upper connection, 
only two hoses are required in cutting, the oxygen 
pressure is regulated to from 25 lbs. to 55 lbs., de- 
pending on the thickness of the material to be cut. 



The oxygen for use in the pre-heating flame is reg- 
ulated with the little needle valve. 75 lbs. pressure 
is too much to operate the preheating flame, and 
the needle valve is used to cut down the flow of 
gas that goes through the pre-heating flame. The 
preheating flame should be regulated to about the 
same general appearance as the welding flame, that 
is, a short blue innercone in a long light blue outer 
flame. The cutting tip should be held about ]/% 
to % inch away from the metal to be cut and when 
the metal is at a melting heat, the lever valve is 
pressed which starts the jet of oxygen through the 
cutting tip. All kinds of steel and wrought iron 
will be readily cut if directions are carefullv fol- 
lowed. Do not hold the torch too close to the metal, 
nor yet too far from it ; if the torch is held 
too close the chances are that the torch will flare 
out ; if it is held too far from the metal the cut will 
be too wide and ragged ; in order to get a smooth 
straight cut hold the torch close to the metal and 
move it at an even rate across the feed, from side 
to side as tipping it one way to the other produces 
a ragged uneven cut. In order to start in the center 
of the metal it is necessary to heat a spot to red- 
ness, then turn on the oxygen 'jet slowly until the 
cutting action is started, gradually increasing the 
flow of gas and also drawing back the torch head 
away from the metal several inches so that the 
metal does not fly back and block up the flow of 
gas. After the first hole is punctured the torch 
may be held down close to the metal again and the 
cutting" continued. 



CHAPTER IX. 

REGULATORS AND INDICATORS. 

On each piece of mechanism necessary to com- 
plete an oxy-acetylene welding plant, depends a 
certain amount of responsibility, and the automatic 
oxygen and acetylene regulator is no exception to 
the rule, for the duty of these regulators is to reduce 
the gas pressure from 1800 lbs. more or less, to as 
low as 1 lb. per square inch, and must at the same 
time and under all conditions maintain an even 
and steady neutral flame. Our regulators are man- 
factured in our factory where none but the highest 
grade of material is used and the best of machinists 
and engineers are employed. These regulators are 
equipped with pressure indicators of high and low 
pressure, one to indicate the amount of unconsumed 
gas in the tank, and the other to indicate the work- 
ing pressure of the gas at the torch. 




Showing automatic oxygen regulator with in- 
dicator for medium pressure drum up to 500 
lbs., also indicator for working pressure. 
For high pressure drums regulator is exactly 
the same, but drum indicator shows pressure up to 
3000 lbs. 

On the low pressure 300 lbs., 100 foot oxygen 
drums, the 500 lb. gauge is used to indicate the 
amount of the unused oxygen in drum, and on the 
high pressure oxygen cylinders that carry a pres- 
sure when filled of 1800 to 2000 lbs., a 3000 lb. 
gauge is used for this purpose. The word "Vul- 
can" on any welding apparatus is your assurance of 
the highest quality. 




Automatic Acetylene regulator with indicator 

which insures steady working pressure and 

even flow of gas. Made of best materials 

and fully guaranteed. 

How to use these regulators is shown with 
generator plants and compressed gas plants on 
pages 45 to 48 of Chapter 10. 



-45- 



CHAPTER X. 

COMPRESSED GAS IN DRUMS. 

From the first small plant which our factory 
produced until the present we have been very suc- 
cessful with plants having two drums of oxygen 
and two of acetylene, one for use and one for ex- 




Valve on top of oxygen drum should be opened very 
slowly and left wide open while in use. 



change of each gas. These plants are convenient 
for portable and stationary work. Gases are al- 
ways ready, no time lost and while the acetylene 
gas costs more, for the man who does an ordinary 
amount of work these plants will probably always 
be desirable. 




Vulcan Xo. 2 portable plant, showing low pressure oxygen 
drums. 

Directions how to operate. 

Connect oxygen regulator 1 to oxygen drum 
valve 2. Connect hose to regulator 1 and to torch 
valve 3. Connect acetylene regulator 4 to acet- 
ylene valve 5. Connect hose to regulator 4 and 
torch valve 6. Unscrew reg. valve stems 7 and 8 
until they do not bear on the spring inside. This 
will close the regulator and prevent any passage of 



gas when drum valves are opened. Now open drum 
valves 2 and 5 and torch valves 3 and 6. Screw 
down regulator valve stem 8 until gas flows from 
the torch tip and light gas. Continue to screw 
down stem until the flame is just on the point of 
leaving the end of the tip. Now screw down ox- 




Showing high pressure oxygen drums containing 200 cu. 
ft. each. Weight of these 200 cu. ft. oxygen drums ap- 
proximately same as low pressure 100 cu. ft. drums thus 
saving one half of freight expense. Cut also shows two 100 
cu. ft. acetvlene drums. 



ygen regulator stem 7 and the flame will immed- 
iately become a brilliant white. More oxygen will 
shorten the brilliant flame and produce an outer 
bluish flame. The inner white flame will gradually 
become smaller as the oxygen is increased, until a 
small cone whose length is approximately three 
times its diameter is formed. Immediately upon 
obtaining this cone no more pressure should be 
given to the oxygen. This is called a neutral flame 
and should be maintained at all times when weld- 
ing steel or cast iron. If an excess of oxygen or 
acetylene is used the metal is rapidly oxidized or 
carbonized, resulting in weak and brittle welds. In 
welding aluminum or brass the welding or inner 
cone may be made longer by an excess of acetylene 
as these metals do not readily absorb carbon. If 
the welding cone is short and stubby the pressure 
on both gases should be increased. If the flame 
blows away from the tip the pressure should be re- 
duced. If the torch flashes back increase the pres- 
sure on both gases. 

When operating acetylene generator instead of 
compressed gas in drums follow carefully direc- 
tions in Chapter VII on generator and operate acet- 
ylene, oxygen and torch valves exactly the same, 
as in this outline, and where directions call for 
operating acetylene drum use generator in its place. 



-49— 



CHAPTER XI. 



PREHEATING. 




r/G. // 2?—'~ 



1) Preheating when necessary of broken parts 
to be welded. 2) Adjusting of flame in blow torch 
so that operator uses the neutral flame, which 
means avoiding carbonization or oxidization of 
metal. 3) Annealing or cooling off slowly, after 
weld has been made, covering weld with lime, 
ashes or asbestos board so that weld cools about 
as slowly as when being heated and 4) finishing, 
practically covers with exception of boiler and a 
few other lines of work, the whole field of welding. 

Let us state, first of all, that expansion and con- 
traction cannot be overcome by force ; the phe- 
nomena manifest itself, and it is perfectly useless to 
try to oppose it. The method is to avoid or limit 
its consequences. 

Let us take a general example : — Here is a weld 
to be executed in the middle of a long bar (fig. 10). 
The dimensions are not important. No bad effects 
of expansion or contraction are to be feared when 



—50- 



it is free to expand or contract. No precautions are 
necessary to overcome the expansion and contrac- 
tion in this case. 

On the contrary, the same bar, having the same 
break, and in the same place, is now situated, for 
example, in the middle of a frame (fig. 11). What 
is now the position? 

No bad effects of expansion need be feared, 
since, on heating to fusion the edges to be welded, 
the expansion takes place and the edges to be weld- 
ed approach each other, the metal in fusion offering 
practically no resistance to this expansion. 

But the weld is completed, and the metal com- 
mences to cool and contract. Now the bar which 
was free to expand does not offer the same freedom 
to contraction since the two extremities of the bar 
are fixed solidly to a frame which was not previous- 
ly heated and consequently is unchanged. 

If the metal is ductile, and elastic, the contrac- 
tion of the parts heated will not produce a break, 
but simply a deformation or strain corresponding 
to the linear value of the contraction. This would 
often be the case, for example, with mild steel. If 
the piece was of cast iron, cooling would probably 
produce a break, probably in the welded portion. 

A break will frequently occur in those metals 
which are ductile at ordinary temperatures but 
whose strength, when hot, is extremely low — cop- 
per, for example ; it takes place during cooling in 
that part which remains at the highest temperature. 

The realization of welds in such metals is pos- 
sible. All that is required is reflection and adjust- 
ment. 

One could raise the whole piece to a high tem- 
perature before welding, and thus produce expan- 



sion in the entire mass, and in this way equal con- 
traction. But, as a matter of fact, complete heating 
is not necessary. It is sufficient to heat, simultan- 
eously with the operation of welding, the parts 1 
and 2 of the frame and thus obtain equal expansion 
to that of the broken bar; then, on cooling, the con- 
traction, is of equal importance in the case of the 
two parallel bars and the repaired bar. Therefore 
there is no strain in the metal or break. 

Suppose it were impossible to heat the frame at 
1 and 2. Other methods are at the disposal of the 
welder; for example, a slight separation of the two 
bars 3 and 4 by bending separates the two edges to 
be welded. This done, proceed to weld, and at the 
end of the operation, that is to say, as soon as con- 
traction commences, due to cooling, remove the 
keys, wedges, or screw jacks from between the 
sides 3 and 4. The return of the bent bars to their 
original position annuls the effect of contraction in 
the welded bar, and thus welded it should be free 
from strains, deformations, or breaks. 

Another method is, although the success de- 
pends upon the thickness of the metal, to cut the 
frame at 5, execute the weld of the bar, and then 
weld at 5, the effects of contraction being least to 
be feared at this part. That is to say, sometimes 
we have to break a piece in order to repair it. 

This example, taken from a hundred, shows the 
importance which the welder should attach to fore- 
seeing the effects of expansion and contraction dur- 
ing the execution of the weld and on cooling. And 
this is evidently part of the "preparation of pieces," 
since it is not possible to guard against the conse- 
quences of these phenomena once the welding has 
commenced. 



-52- 



The devices to be followed vary in each case. 
We will study them in greater detail in the chap- 
ters devoted to each metal, but it is useful to em- 
phasize that the phenomena of expansion and con- 
traction are enemies of the welder; that in all welds 
means must be devised to prevent their effects and 
avoid their consequences by means of such meth- 
ods as we have indicated. 

It is very often not only more economical 
but absolutely essential to preheat the work before 
welding. It must be remembered that oxygen and 
acetylene gases are more expensive than most other 




Showing position of crank shaft placed on "V" blocks 
ready for weld. 

means of heating the work. Where it is desired to 
weld a large casting or forging, the speed of the 
operator can be greatly facilitated by heating the 
work in a common blacksmith forge, or in a rough 
brick oven built around the work, when charcoal 
is used. A common oil blow-torch can also often 
be used to advantage. 



-53- 



In most cases the principal reason for preheating 
is to overcome the effects of expansion and con- 
traction. It is a well know fact that when metals 
are heated they expand, and when cooled, contract. 
Thus a steel bar twelve inches long at 100 degrees 
Fahrenheit will increase more than an eighth of 
an inch in length if heated to 2,100 degrees Fahren- 
heit. 

As a common example, let us take a spoke of a 
fly wheel that has had a piece broken out of it. This 
piece just fits into its place. If this piece is welded 
in place without proper preheating, the expansion 
may be sufficient to crack the rim of the wheel, or 
when the spoke cools there will be sufficient con- 
traction so that a break will occur in the weld or 
some other point. To overcome this expansion and 
resultant contraction in this instance, the broken 
part of the spoke should have been bevelled off, 
ready for welding, and then clamped in place. We 
.should then have heated to a red heat the broken 
spoke, the adjacent spokes and the intervening rim. 
It is not necessary to bring every part to the same 
temperature, but seek to have it shade off. Other- 
wise, the preheating might produce stresses and 
strains too severe to be endured without breakage. 
Consequently, when the new material is filled in to 
make the joints, the spoke will be longer than need- 
ed at atmospheric temperature. It has, however, 
an opportunity for contraction, because it and the 
adjacent spokes are going back to normal size to- 
gether, and when it is not too large, the entire 
casting should be preheated. All preheating of 
this character should be done slowly, so that the 
expansions will have time to distribute themselves. 
If the work is heavv the outside will heat before 



-54— 



the interior. When such conditions exist there is 
danger of having breaks. The remedy is to heat 
slowly, so that within and without the distribution 
of heat may proceed in a fairly uniform manner. 
A slow heating' is especially to be advised where 
there is a combination of thin and heavy parts. 

After the welding- has been completed it is ad- 
visable to cover the work with sheet asbestos, so 
that it will cool gradually. This, for the same rea- 
son, is just as essential as slow and gradual heat- 
ing. From the writer's experience, what is known 




Illustration K. 



as one-eight inch asbestos roll board is most suit- 
able. Covering in dry, heated, slaked lime has also 
been found quite satisfactory. 

Cuts K and L illustrate tables made of angle 
iron welded together. The top is covered with fire 
brick, on which suitable ovens of the desired shape 
can be built. Angle iron used is 2" x 3" for the 
ordinary sized table and the top of the oven is gen- 
erally covered with heavy asbestos paper board to 



confine the heat. After the charcoal fire or gases 
have brought the metal up to a point where it is 
slowly expanding, keep it covered until it is fully 
expanded when it will best respond to the welding 
flame. Cast iron and steel should be heated to a 
dull red before beginning to weld whenever a cast- 
ing of these metals requires preheating. 




i 



Illustration L. 




Figure 12. 



Figure 13. 



Figure 24. 



The effect of expansion acts in such a manner that the 
edges to be joined separate and approach each other alter- 
nately. 

If one wishes to join two plates by autogenous welding 
and the edges have been arranged parallel, when the weld 
has commenced one first observes a widening at the other 
end of the plates (fig. 13). If the welding is continued, 
the deviation quickly stops and the opposite movement is 
produced, that is to say, the edges approach each other fig. 
12 (. On continuing the operation, expansion leads to the 
overlapping before the completion of the weld (fig. 14 . 



CHAPTER XII. 



GENERAL WELDING INSTRUCTIONS. 



CAST IROX WELDING 



In welding thin cast iron section? such as auto- 
mobile cylinders, manifolds and the like, it is not 
necessary to chip out the piece where the fracture 
occurs as the flame will penetrate a thickness of 
Y% inch very easily and an inexperienced welder 
can almost invariably make a satisfactory- job with- 



out going to the trouble and expense of chipping 
out the crack. However if the piece is to be fin- 
ished up or machined in any way it is better to chip 
out the fracture and introduce new metal in place 
of melting up the old, thus having new metal en- 
tirely to file or finish rather than the more impure 
metal of which the casting is made. It will be 
found much softer to work. In welding circular 
sections it is almost always necessary to chip out 
the crack or blow it out with the heat of the torch, 
this should be made into a "V" shape groove and 
then entirely filled with new metal from the filler 
rod. In welding any complicated castings always 
preheat them all over a dull red heat. This is al- 
ways a safe rule to follow when in doubt as to pre- 
heating. After a welder has acquired considerable 
experience it is not always necessary to preheat the 
casting all over, and the more experienced a welder 





Illustration showing one-half saving in bevelling weld 
from both sides when possible; "E" "F" spaces being 
equal to "A" "B" spaces; and "C" and "D" extra 
spaces to be filled when bevelling from one side. 



-58- 



becomes the less preheating he will do in order to 
secure a good job. However a beginner should never 
be allowed to weld a complicated casting without 
preheating it as he will almost certainly fail. Hard 
spots in cast iron welding has been one of the most 
difficult points to overcome, even experienced weld- 
ers have trouble in this manner. One of the causes 
for hard spots appearing is using too much flux 
or scaling powder. Scaling powder or flux should 
be used as sparingly as possible, using too little 
rather than too much, just enough should be used 
however to make the iron flow freely and to break 
up the scum on the surface. The cause for large 
areas of hard spots is the welding or the melting of 
metal on cold iron. If a heavy piece of cast iron is 
being welded and it is not hot enough it will chill 
the metal added, thus producing the hard spots, 
which is the same result as chilling castings. Car 
wheels are cast in iron chills, thus producing a 
very hard surface which is required on the periphery 





Bevelling of pieces from %// to ^" in thicknt 
Bevelling for thickness in excess of 1 / 4 // - 



-59- 



of the wheel. This same result is produced by melt- 
ing metal on a cold piece of iron. Another puzzle 
to a great many welders is the appearance of a small 
round hard spot about an l /% to J /± inch in diameter 
in an otherwise perfectly soft and good weld. This 
is caused in the following manner and it has taken 
a great deal of study to find out the exact reason 
for it. In welding a large casting the welder usual- 
ly melts a small pool of metal and inserts the cast 
iron filler rod in it, gradually melting it all and fill- 
ing up the fracture. Now if the cast iron filler rod 
is cold and it is inserted into this pool of moulten 
metal it will chill the metal surrounding it, produc- 
ing the same results as if the hot metal was welded 
on a cold metal surface. It is almost impossible to 
get this spot soft again by melting it up, the metal 
filler rod should therefore be almost melting be- 
fore it is inserted into the pool of moulten metal ; 
however the metal filler rod should not be held 
away from the piece to be welded and metal melted 
off and dropped through the welding flame, as the 
welding flame is so intensely hot that it would burn 
the metal as it passed through the flame. The filler 
rod should always be in contact with the piece be- 
ing welded but it should always be almost at the 
melting point. 

Malleable casting' has always been a source of 
trouble to welders since, in welding the metal 
is changed back to ordinary cast iron. Malle- 
able castings are of course made of cast iron 
and then treated in ovens for several davs which 
produces the malleability. In welding malleable 
castings the metal of course is melted and the car- 
bon becomes evenly distributed again and the piece 
is converted back to ordinarv cast iron ; therefore 



-60— 



in order to weld malleable casting we must obtain 
some process by which the malleable piece need not 
be melted. This is accomplished in the following 
manner. Piece to be welded is ground out at the 
fracture so there is a groove at an angle of about 
90 degrees, in fact this must be like a trough, the 
piece is then heated to a red heat, then sprinkled 
with bronze .flux and it is necessary to see that the 
surfaces are clean and bright. When the pieces are 
at a dull red heat a small drop of Tobin bronze is 
melted off into the trough. If it lays in the trough 
in the shape of a small ball the casting is not yet 
hot enough but if it spreads out and adhers to the 
surfaces the piece is hot enough and the grooves 
should quickly be filled up. The piece should not 
be kept hot longer than necessary as the longer it 
is kept hot the more brittle it will become. An ex- 
perienced welder can weld a malleable casting and 
the result will be practically as good as a new 
piece, in fact it will bend just as good if not better 
in the weld than it will at other places. It is also 
quicker to weld a piece of this sort than it is to weld 
a cast iron piece as the bronze can be flowed in very 
rapidly after the welding is once started, although 




Bevelling and welding of thick pieces when practicable 
to work from both sides. 



—61- 




Eesults of welding a cylinder when the body has been 
previously tacked produce the deformation shown. 




=# 



A 



The proper method of welding steel cylinders, removing 
the wedge as the weld progresses. 



1 



the bronze filler rod is much more expensive than 
cast iron filler rod. In welding gear teeth and in 
welding cast iron vertically there is considerable 
difficulty experienced as cast iron will, upon welding, 
pretend to run away. This may be overcome a great 
deal by using graphite blocks cut and ground to 
shape to fit the piece being welded. 

In foundries, in repairing defective castings, sand 
cores are made up and inserted in the defective 
castings and new metals melted on the sand core 
which acts as a support for the moulten metal. The 
sand cores may be then broken up and removed. 
In cases where a malleable casting cannot be ground 
out it may be reinforced with a small strip of 
steel, welding along each side of the steel after hav- 



ing welded up the break, always demembering that 
the longer a malleable casting is heated the more 
brittle it will become until it is finally reduced to 
ordinary casting. In welding a strip of steel to a 
malleable casting, cast iron filler rod should be used 
although an experienced welder often uses a small 
steel wire. 




Illustrations 20 and 21. 




Illustrations 22 and 23. 




I 



Illustrations 24 and 25. 
—63— 



Illustrations 26 and 



Nos. 20 to 27 Inclusive. 



Illustrating the different methods in preparing joints for 
welding in sheet metal and boiler work. 



STEEL. 

In welding steel the beginner will almost in- 
variably try to weld by getting it only red hot 
and then dropping a few drops of metal off of the 
filler rod onto the steel pieces and then trying to 
work it in to make a weld. This is entirely the 
wrong proceeding, the pieces to be welded should 
first be heated to a moulten state at the place to 
be welded, then the filler rod inserted in the moulten 
metal and the tip of the cone of the flame placed 
first on the steel pieces then on the end of the filler 
rod, gradually melting off the filler rod and filling 
up the cracks or the joint In the first place if the 
steel filler rod is melted off and the moulten metal 
allowed to drop through the flame the small drops 



—64— 



of metal become extensively heated and burned, 
while if the filler rod is in contact with the piece 
being welded the heat is conducted off to the larger 
piece and the metal remaining practically cool. 
Then again if the drops of moulten metal are al- 
lowed to drop on the steel for this welding" it is very 
difficult to make a homogeneous joint, but if the 
steel is melting and the filler rod is put in the pool 
of moulten metal a good joint will be insured. It 
is always advisable to chip out the crack before 
starting to weld. After welding about three inches 
the metal should be heated on each side of the weld 
to a dull red heat until the weld is cold, then a slight 
tapping or pounding with the ball pein hammer on 
the heated part of the metal is advisable in order to 
stretch it as it cools, which helps to take care of the 
contraction ; then continue to weld up three more 
inches and again heat the metal on each side of the 
weld. Proceed along this Avay until the entire weld 
is completed. Putting in a patch it is well to cut 
out the piece in a circular shape if possible putting 
in a new piece cut to fit and dish very slightly. 
Then after the weld is completed and the metal be- 
gins cooling the dished patch should be hammered 
in order to help take care of the contraction ; this 
prevents the welded part from opening up. Many 
welders have better success by putting on a lap 
patch in place of a butt patch. In a large patch it 
is necessary to cut out the metal in back of the 
patch that is put on, otherwise the patch will be 
quickly burned through. Experienced welders weld 
cracks in boilers overhead as easily as on the side, 
but this requires time and experience to learn. 



-6.5- 



BRASS AXD BRONZE. 

In welding" brass or bronze the pieces should be 
chipped out or ground out at the fracture the same 
as welding cast iron and then the groove should be 
rilled in with manganese bronze ; before filling in 
with manganese bronze the pieces should be well 
coated with bronze flux, which acts as a coating 
and keeps the oxygen of the air away from the 
metal, as this metal oxidizes very rapidly under 
intense heat. Copper, brass and bronze pieces re- 
quire a larger tip than cast iron and steel pieces 
as the conductivity of this metal is much greater, 
copper especially requiring greater heat. 

ALUMINUM WELDING. 

While the melting point of aluminum is approxi- 
mately 1,200 degrees Fahrenheit, or about half that 
of cast iron, it is much more difficult for the novice 
to weld satisfactorily. Cast aluminum is compara- 
tively weak in a tensional direction, and it possesses 
a high rate of expansion and contraction. Its ther- 
mal conductivity is quite high, being comparable 
with that of copper. In welding aluminum its ex- 
cessive expansion and contraction must constantly 
be kept in mind. On account of the low melting 
point of aluminum this expansion takes place very 
rapidly, and great care must be taken when pre- 
heating aluminum castings for welding. Care must 
also be exercised to see that the pre-heating tem- 
perature does not exceed 1,200 degres Fahrenheit, 
as any higher temperature will result in melting 
the entire casting. , 

Some writers advocate the use of a flux for weld- 
ing aluminum. This is entirely unnecessary, and. 



-G6- 



in fact, better welds can be made by an experienced 
"puddle" welder. By "puddle" welding of aluminum 
is meant that the aluminum is scraped oft with a 
small steel rod flattened at one end, and additional 
aluminum from a welding rod is melted into the 
cracks. This additional aluminum is then w rke I 
or "puddled" by means of a steel rod. the oxy-acety- 
lene flame being used to keep the metal in a suf- 
ficiently molten state to permit mixing the added 
metal thoroughly with the part being welded. As 
the fusion point of aluminum is very low, the op- 
erator must bear in mind that it is necessary to 
keep the working flame further away from the metal 
than is usually the case with cas: iron <>r steel. It 
is also advisable to adjust the torch s as tc furnish 
an excess of acetylene, as there is practically no 
danger of carbonizing the metal, since molten alum- 
inum will not absorb carbon. 

Aluminum solders : — The numerous alloys of the 
aluminum — copper-tin or copper-tin-bismuth type — 
which have been used for soldering aluminum at 
moderately low temperature, are all open to the 
same objection — that the soldered joint slowly I 
its hesion; i. e.. its mechanical strength. This 
is due to the fact that aluminum, particularly in 
the presence of water, compares unfavorably with 
other metals on account of the "electrolytic local 
action." the aluminum becoming slowly decom- 
| - : I 

The manufacturer of cheap welding apparatus 
cares little or nothing about the success of the user, 
being satisfied with a large profit on the first sale. 
The manufacturer of high grade welding apparatus, 
however, takes every reasonable precaution to see 
that the purchaser succeeds by providing personal 



instruction, the usual charge being five dollars per 
clay where the purchaser goes to the plant of the 
manufacturer. This charge is made to cover cost 
of gases, materials used, time of instruction, etc. 
Ten dollars per day and expenses is the usual charge 
where an instructor is sent out with the plant. In 
a few instances manufacturers provide the pur- 
chaser with personal instruction in their own works 
without extra charge. The advantages of this can 
readily be appreciated, as many valuable "shop 
kinks" can be picked up that cannot be shown in 
a book of instruction. In addition, free gases are 
furnished, and this alone is worth several dollars 
each day. 

Another matter of importance is the use of the 
proper welding rod for the particular work in hand. 
The same thing" may also be said of fluxes. There 
are several cheap, so-called fluxes on the market, 
but it is much safer to go to a reliable manufac- 
turer of apparatus and get your supplies from him. 
Your extra initial expense will be more than justi- 
fied by the increased certainty and quality of your 
success. It is very poor economy to do poor work 
rather than pay a reasonable price for high grade 
supplies. 

MELTING POINT OF METALS. 

Centi- Fahren- 

grade heit. 

Tin : 232 499 

Bismuth 348 504 

Lead 327 620 

Zinc 478 787 





_ _ 643 


1.214 
1.200 


Aluminum 


- _ _ 635 


Magnesium 


_ _ _ 785 


1.472 


Bronze 


._ 90S 


1.692 


Silver 


940 


1.751 


Gold 


_. 1,072 


1.747 


Copper 


1,082 


1.943 


Xickel 


.....1.412 


2.600 



Cast L 



White 


_ 1.100 


2.075 


Grav 


.._ 1.200 


2,228 


Steel. 

Mild _ 


1.375 


^.'-o' 


Hard and 

Wrought Iron 

Platinum 


1.600 

..1.775 


2.737 
3.110 


Iridium _ 


1.950 


3.542 
3,632 


Rhadium 


_ -2.000 



CHAPTER XIII. 
WELDING RODS AND FLUXES. 

For welding ordinary wrought iron, steel plates, 
steel forgings and castings, the best results are 
obtained by using as the weld feeder the imported 
soft Swedish iron wire as free from carbon as pos- 
sible. Some welding supply houses have special 
steel welding rods manufactured after their own 
formulas. These rods are somewhat higher priced, 
but the best results obtained from a good steel 
welding rod are well worth the extra cost. 

For cast iron welding, specially prepared rods of 
cast iron, containing approximately 3% silicon, are 
employed. On account of the impurities in the or- 
dinary cast iron casting, it is usually found advan- 
tageous to employ what is commonly known among 
welders as a "scaling powder," or cast iron weld- 
ing flux. The purpose of this flux is to bring the 
impurities to the surface and prevent blow-holes. 
Pure aluminum rods of suitable size are used in 
welding aluminum. 

Manganese and Tobin bronze are used quite ex- 
tensively for welding brass, bronze and malleable 
castings, although, as a general rule, it has been 
found inadvisable to weld malleable casting sub- 
ject to any great strain. The reason for this is that 
when the casting is heated to the point of fusion 
the metal is converted back to ordinary gray iron. 
Fair success, however, can be obtained by using a 
special bronze welding rod, and even ordinary cop- 
per wire has been found quite satisfactory. 

Malleable iron, if thin and not varying too 
much in thickness, can be welded as previously out- 
lined but when thickness varies considerable it re- 
quires the services of an experienced welder. 



CHAPTER XIV. 

METALS AND THEIR PROPERTIES. 
STEEL. 

Both mild and hard steels are alloys of iron and 
carbon. Carbon is united with iron in proportion of 
.05 (mild steel) per cent to 1.5 per cent (extra hard 
steel). 

Increasing the carbon diminishes ductility and 
malleability of the alloy. Steel melts at 2532° to 
2737° Fhr. The chief enemy of good steel weld- 
ing" is oxidation. Steel is generally conisdered the 
easiest of all metals to become expert in and yet 
because of ease and the good looks of the weld, 
welders are often deceived. The oxygen of the air 
rushes in on the metal bath. Combustion is going 
on rapidly and water vapor is frequently the result 
of it. 

Water vapor is found with even' welding flame 
but in less quantity with acetylene gas than other 
gases. Melting iron or steel invariably leaves a 
small coating of oxide of iron when blowpipe is 
used. Iron in molten state dissolves 1.1% of oxide. 
This oxide is frequently found in the mass of the 
weld. Frequent heating of parts around the weld 
so that cold air is excluded from the weld, anneal- 
ing and hammering of weld making the texture of 
metal of much finer quality, all tends to produce 
the lasting and best weld. 

CAST IRON. 

Iron used for casting generally contains 3 to A c /c 
of carbon. Hardness or brittle weld is the chief 
difficulty in welding cast iron. A small per cent of 
Silicon in the welding rod, slow cooling, absence 



-71- 



of manganese and avoiding sudden cool air chills 
when welding all help to produce the soft-weld 
which is necessary for finishing. A good flux will 
destroy the oxide or scales, and it also cleanses 
the metal to he welded and thus aids in the weld- 
ing. Read the chapter on pre-heating, chapter 12, 
when getting posted on cast iron welds. 

The field for autogenous welding of cast iron is 
very wide, in fact as various as the many kinds of 
castings ; the foundry is every day finding new uses 
for this' important work. 

COPPER, BRASS AND BRONZES 

are fully as successively welded with the blowpipe 
as are cast-iron and steel. ' Special welding rods 
are frequently of more use than fluxes with these 
metals. Pure copper with small per cent of phos- 
phorus and aluminum is one of best rods to be 
used. Pre-heating is generally required with these 
metals. Hammering after welding is practical, af- 
ter hammering reheat and then cool quickly. 

Brasses being an alloy of copper and zinc, have 
under the blowpipe three distinct phenomena- — ■ 
namely, absorption of gases, volitization of zinc, 
and oxidation. Special welding rod and a clean- 
ing flux are great helps in good work. 

The welding rod should have a small per cent 
of aluminum in its makeup to deoxidize the weld. 

Uniformity should mark the work of adding 
aluminum after casting. Borax is not a good flux 
for this metal. Sodium chloride, borax and boracic 
acid as used in red copper are found to be satisfac- 
torv. 



Bronzes are alloys of copper and tin. Special 
welding rod and flux are essential for best welding. 
Avoid brass wire in welding bronzes. As in cast 
iron, bronzes are similarly treated and prepared us- 
ing however, the special rods and fluxes as sug- 
gested. 

GOLD, SILVER AND PLATINUM 

all yield readily to the great heat of the oxy-acety- 
lene flame. Gold melting at 1747° Fhr., silver about 
the same while platinum at 3110° Fhr., are fre- 
quently worked by this flame in a more successful 
way than any other known form. 



-73- 



CHAPTER XV. 

BOILER WORK. 

This is one of the most important branches of 
oxy-acetylene torch practice and unless the oper- 
ator has become thoroughly proficient in the use 
of the torch he should not undertake this work. 

It is difficult to lay down any set rules or in- 
structions for boiler welding but the suggestions 
that follow may be of aid to the inexperienced. 

The facility of execution in boiler work, as well 
as in practically all welding, depends in a large ex- 
tent on the preparation of the parts to be joined. 
As is described elsewhere in these instructions, it 
is often advantageous to bevel the edges to be 
welded so as to facilitate the execution of the work 
and make sure of melting the metal throughout the 
entire thickness of the metal. This it is best to do 
when it is necessary to fit a patch in the side sheet 
or similar work. It is much easier for the operator 
however and it has been found more practical in 
welding on patches, to cut the patch to be welded 
on, large enough, so that it laps over the sheet on 
which it is to be welded. Before commencing to 
weld the patch on it should be dished sufficiently 
to take care of the contraction after the welding 
has been completed. As an illustration, suppose 
that the piece cut out of the sheet is 2 ft. x 3 ft. 
The patch should be large enough so that it will 
lap over at least one half inch all around making 
the total width and length of the patch one inch 
wider and longer than the hole in the sheet. Then 
if the patch is slightly dished and welded in place 
so that the convex side is toward the operator, it 



can be heated for some distance around the center 
and hammered down while the weld around the 
outside is cooling and contracting. With a little 
experience the operator can easily determine how 
much a patch, of a given size, should be dished to 
take care of this contraction. It is also important in 
cutting the piece out of the side sheet that the hole 
is cut so that the edge of it will be as far away from 
the adjoining stay bolts as possible. The reason 
for this is that when the weld cools off, the resultant 
contraction will draw the metal away from around 
the stay bolts and cause leaks. Therefore the edge 
of the patch, where welded on to the sheet, should 
be at least an inch, or more if possible, from the 
adjoining stay bolts. If, however, a leak should be 
found around any of the stay bolts they can be 
welded to the sheet and additional metal should be 
added to reenforce the weld to take care of the 
strain caused by contraction when cooling. 

Cracks in fire doors and mud rings can very easily 
be welded as these cracks usually occur in such a 
position that the contraction will almost always 
take care of itself without any great precaution. 
Every welder before attempting to make an actual 
repair on a boiler,' such as putting on a patch, 
should spend considerable time practicing welding 
on odd pieces of steel plate of about the same thick- 
ness as boiler plate. These pieces should be placed 
in a perpendicualr position and welded together 
while in that position. Until the operator can 
make first class welds in practice he should, under 
no circumstances, attempt such important work as 
welding a patch in a side sheet or fire box. 

Overhead welding should also be practiced as a 
great deal of this is necessary in boiler repairs. It 



is of course always best to thoroughly clean the 
parts to be welded as rust, scale and dirt, when 
mixed with the molten metal, tend to weaken the 
weld to a considerable extent. Only the best grade 
soft, toug-h steel welding rods should be used. 
Three sixteenths and one quarter inch diameter 
rods are the most suitable sizes. Some dealers have 
rods made up for this special purpose, and when 
possible, these should be procured. 

As previously stated it is difficult to lay down 
any set rules. Practice, experience and good judg- 
ment are, however, absolutely necessary, and this 
class of work should never be undertaken by the 
beginner. 

The oxy-acetylene torch can be used very suc- 
cessful for re-tipping' flues. By the old method 
flues and tips were scarfed ; brought to a welding 
heat in the blacksmith forge and then welded by 
means of hammer blows. To do this work properly 
it would therefore require the services of an experi- 
enced blacksmith and in comparison to the new 
method takes considerable longer. While not ab- 
solutely necessary flues can best be retipped by 
means of the oxy-acetylene torch by first grinding 
or filing the ends of the flue and. tip to a bevel edge, 
butting the beveled ends together and welding them 
in place. Care must be taken not to allow the metal 
to flow through and leave a rough edge on the in- 
inside. Should this occur, the end of the flue could 
be slipped over a piece of round shafting to be 
used as a mandrel, and hammered smooth. Very 
little extra metal should be added on the outside 
otherwise the flue would not pass through the flue 
sheet. 

Where a pure supply of water is available, that 



is where the water is not alkaline leaving lime de- 
posits in the boiler, it has been found practicable to 
weld the flues directly to the flue sheets. When 
they are so welded, it is of course difficult to take 
them out and hence it is not recommended where 
it is necessary to frequently remove the flues on 
account of corrosion or lime deposits from alkaline 
water. 

In welding" new flues to the flue sheet, they 
should be welded on one end only, the other end be- 
ing rolled. The welding should be done first leav- 
ing the other end free to take care of the expansion 
and contraction. The flue should be allowed to 
extend through the flue sheet about one-eighth inch 
or three-sixteenths inch and then welded around 
between the end of the flue and the sheet. 



CHAPTER XVI. 

CARBON DESTROYED IN CYLINDERS 

Carbons deposits frequently form in the com- 
pression chamber of internal combustion engines. 
Excessive deposits cause knocking and loss of 
power. To remove this carbon bv the old method 
of scraping takes a long time, especally when it is 
necessary to remove the cylinder to get at the 
carbon. 

By means of the Vulcan oxygen carbon remover 
these deposits can be removed in but a small frac- 
tion of the time that is required by scraping. 

DIRECTIONS FOR USING "VULCAN" CAR- 
BON BURNER. 

Remove spark plug and valve cap. Have piston 
at top of compression stroke and with piston at 
head of cylinder, position is right for practical 
work. 

Inject in valve chamber and cylinder head, a 
small quantity, say one-half teaspoonful or so, of 
kerosene and after soaking carbon a minute or so 
light with a match or small torch and immediately 
insert "Vulcan" Burning Torch into valve cham- 
ber, press lever and allow a small quantity of "Vul- 
can" gas to mix with kerosene flame. 

This, at first, will produce quite a flame com- 
ing out of opening and while kerosene is burning 
allow "Vulcan" gas to mix in chambers and soon 
instead of a clear flame will be carbon sparks com- 
ing out of opening', the gas eating all carbon de- 
posit in cylinder walls, piston and valve heads, the 



flame continuing until all carbon is removed down 
to the metal itself. 

When torch is in chamber turn it into every 
part of opening" so that there is not a spot left 




Oxygen Carbon Burner at Work. 

where gas has not had opportunity to meet the car- 
bon. 

"Vulcan" oxygen gas delights in eating carbon 
deposit in any form. 



-79- 



If kerosene flame goes out, put small quantity 
in chamber again and light over again. 

This sometimes has to be repeated once or twice 
but once one has learned how, it's very short work 
to clean all parts thoroughly. 

After first cylinder and parts are cleaned pro- 
ceed to others same way. 

In a very short time you will be able to do the 
four on an ordinary automobile in less than 20 min- 
utes. 

Keep face away from valve openings while 
cleanings as sometimes gases mix and unexpected- 
ly flame out of opening with considerable noise. 

This process does not over-heat cylinders at all ; 
in fact, they are not as hot as in ordinary usage. 

After cylinder is cleaned blow out loose carbon 
particles with compressed air. 

A "Vulcan" Carbon Burning Tool and com- 
plete equipment will make money for the Garage 
as quickly as any other work that ever comes to the 
shop. 



-80- 



APPROXIMATE WEIGHT AND DIMENSION OF ACETYLENE 
GENERATORS. 



Generator 
of Carbide 


Height 


Diameter 


Weight 


Crated 


Crated size 


25 lbs. 


4 ft. 4 in. 


20 in. 


200 lbs. 


290 


30x28x 56 in. 


50 " 


5 ft. 6 in. 


22 " 


300 " 


420 


' 30x30x 68 " 


100 " 


6 ft. 6 in. 


26 " 


450 " 


590 


32x34x 80 " 


200" 


8 ft. 2 in. 


34 " 


700 " 


850 


40x40x102-" 


300 " 


9 ft. 


42 » 


850 " 


1000 


48x48x112 " 



WELDING PLANTS (Approximate) 



No. 1 


500 lbs. 




No. 2 


600 " 




No. 3 


650 " 


Crated 740. 


No. 3 


840 " 


Mounted on truck. 


No. 4 


750 " 


Crated 875. 


No. 6 


950 " 


Crated 1110. 



WEIGHT OF OXYGEN GAS DRUMS. 



Oxygen Capacity Pressure 


Weight 


Low pressure 
High Pressure 
High Pressure 


100 cub. ft. 
100 " " 
200 " " 


300 lbs. 
1800 " 
1800 " 


150 lbs. 
125 " 
150 " 



ACETYLENE GAS DRUMS 100 CUBIC FT., 150 TO 200 LBS., PRESSURE 
WEIGHT 80 LBS. 



-81— 



Oxy-Acetylene Cutting (Approximate) 
Machine Cutting. 



Tip 


Thickness of 
Metal 


Oxygen Heating 
Gas Pressure 


Oxygen Pressure 
in Cutting 


nches Per Minute 


A 


% 


4 1b. 


10 b. 


30 




y? 
\ 


.. 


18 " 
28 " 


24 
20 


" 


\y 2 


5 1b. 


30 " 


16 




2 




36 " 


12 


B 


3 


" 


40 " 


9 




6 


61b. 


60 " 


434 




9 




90 " 


3^ 





Hand 


Cutting. 






Acetylene Gas Oxygen Gas 
Heating Jets 






Pfr Four 




A 
B 


12.20 

20 

28.20 


12.60 
20.40 
30.10 


3 1b. 

4 " 

5 "' 



Cubic Feet Oxygen Used in Cutting Jets 
Per Hour. 



5 1b. 


10 1b. 


20 1b. 


301b. 


40 1b. 


50 1b. 


75 1b. 


901b. 


32 


41.50 


71 
to 
75 


90 
to 
140 


110 
to 

200 


120 
to 
220 


210 
to 
300 


35( 



Oxygen: at 20° C 
Hydrogen : 
Acetylene: 



WEIGHTS OF GASES. 

F and 760 m/m Pressure. 100 c. f. 



weigh 8.29 lbs. 
0.52 "• 
6.74 - 



VARIATION OF PRESSURES IN CYLINDERS 

WITH VARIATION OF TEMPERATURE; 
QUANTITY OF GAS REMAINING CONSTANT 



Tem- 
perature 


100 CU. ft. 

300 lb. cyl. 
cyl. 


200 cu. ft. 

1800 lb. 

cyl. 


150 cu. ft. 
1650 1b. 

cyl. 


100 cu. ft. 

1 800 lb. 

cyl 


150°F 


350 lbs. 


2090 lbs. 


1887 lbs. 


2090 lbs. 


100 


320 " 


1912 " 


1750 " 


1912 " 


80 


307 " 


1844 " 


1686 '• 


1844 " 


68 


300 " 


1800 " 


1650 " 


1800 " 


50 


290 " 


1736 " 


1596 " 


1736 " 


32 


278 " 


1672 " 


1539 " 


1672 " 





258 " 


1558 " 


1440 " 


1558 •' 


-10 


252 " 


1522 " 


1410 " 


f522 " 



QUANTITY OF GAS IN CYLINDERS UNDER VARIOUS 

PRESSURES: 

TEMPERATURE CONSTANT. 



100 cu. ft. 

1800 lbs. 



200 



ft. 



150 cu. ft. 

1650 lbs. 



100 cu. ft. 
•300 lbs 



Pressure cu. ft. 
at 68° F 



Pressure cu. ft. 
at 68° F 



Pressure cu. ft. 
at 68°F 



Pressure cu. ft. 
at 68° F 



1800 lb 


5. 100 


1800 It 


s. 200 


1650 lbs. 150 


300 lbs 


1620 ' 


90 


1620 ' 


' 180 


1100 


' 100 


270 " 


1440 • 


80 


1440 


' 160 


990 


' 90 


240 " 


1260 • 


70 


1260 ' 


' 140 


880 


' 80 


210 - 


1080 ' 


60 


1080 ' 


' 120 


770 


' 70 


180 '• 


900 ' 


50 


900 ' 


' 100 


660 


• 60 


150 " 


700 ' 


39 


700 ' 


' 78 


550 


' 50 


120 - 


500 ' 


28 


500 ' 


' 56 


700 


' 64.5 


100 " 


300 ' 


17 


300 ' 


' 34 


500 


' 45.5 


75 " 


100 '■ 


6 


100 • 


' 12 


300 


' 27 


50 ' 


18 ' 


1 


18 ' 


6 


100 


9 


25 " 


9 ' 


Vi 


9 


1 


11 


1 


3 - 



100 
90 
80 
70 
60 
50 
40 
33 
25 
17 



Nol corrected for variations from Boyle's Larv 



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3' 




Complete "Vulcan" Acetylene Generator, oxy- 
acetylene welding and cutting- plant. 

Made in sizes from 25 lb. generator size up to 
500 lb. with new 200 cub.- ft. oxygen drums ; freight 
on oxygas gas being less than half with old type 
drum. 



-85- 



A VULCAN 



Welding Torch, 
Acetylene Gener- 
ator, or Complete 
Welding Plant is 
far in advance of 
the average Weld- 
ing apparatus. All 
special features 
are protected by 
patents. Cost is 
lowest consistent 
with greatest effici- 
ency known. 



